How to Get a Screw Out That Broke Off: A Comprehensive Guide

Losing your cool over a screw that snapped clean off? Don’t worry, you’re not alone. This is a frustratingly common problem, whether you’re tackling a DIY project at home, working on your car, or even dealing with delicate electronics. But before you reach for the hammer or drill, know that there are several effective methods to remove that broken screw without causing further damage. This comprehensive guide will walk you through the best techniques, tools, and tips, transforming a potential disaster into a manageable task. We’ll cover everything from the simplest solutions to more advanced methods, ensuring you have the knowledge and confidence to tackle any broken screw situation. Our goal is to provide you with a resource that’s not just informative but also practical and trustworthy, drawing on expert advice and years of hands-on experience.

Understanding the Problem: Why Screws Break

Before diving into solutions for how to get a screw out that broke off, it’s helpful to understand why screws break in the first place. Several factors can contribute to this frustrating situation:

* **Over-tightening:** This is perhaps the most common cause. Applying excessive force when tightening a screw can exceed its tensile strength, leading to breakage.
* **Corrosion:** Rust and other forms of corrosion weaken the metal of the screw, making it more susceptible to snapping.
* **Material Fatigue:** Repeated stress and strain on the screw over time can cause fatigue and eventual failure.
* **Incorrect Screw Type:** Using the wrong type of screw for the application (e.g., using a wood screw in metal) can place undue stress on the screw.
* **Poor Quality Screws:** Inferior materials or manufacturing defects can result in weaker screws that are prone to breaking.
* **Stripped Screw Heads:** Trying to force a driver into a stripped screw head can cause the screw to snap. Pre-existing damage to the screw head is a major cause of breakage during removal.

Understanding these causes can help you prevent future screw breakages. Now, let’s move on to the techniques for removing those pesky broken screws.

Essential Tools for Removing Broken Screws

Having the right tools on hand is crucial for successfully removing a broken screw. Here are some essential tools you should consider:

* **Screw Extractors:** These specialized tools are designed to grip the inside of a broken screw and allow you to turn it out. They come in various sizes to accommodate different screw diameters.
* **Left-Handed Drill Bits:** These drill bits are designed to turn counter-clockwise. As you drill into the screw, the bit may catch and unscrew the broken piece.
* **Penetrating Oil:** Applying penetrating oil can help loosen a corroded or stuck screw. WD-40, Liquid Wrench, and PB B’laster are popular choices.
* **Drill:** A power drill is necessary for using screw extractors and left-handed drill bits. A variable-speed drill is ideal.
* **Center Punch:** A center punch is used to create a starting point for drilling, preventing the drill bit from wandering.
* **Hammer:** A hammer is used to tap the center punch.
* **Pliers (Needle-Nose and Locking):** Pliers can be helpful for gripping and turning small screw fragments.
* **Screwdrivers (Various Sizes and Types):** A selection of screwdrivers is essential for removing any remaining portion of the screw head.
* **Heat Gun or Soldering Iron:** Applying heat can help loosen screws that are stuck due to threadlocker or corrosion.
* **Dremel Tool with Cutting Wheel:** A Dremel tool can be used to create a slot in the screw head for a flathead screwdriver.

Having these tools in your arsenal will greatly increase your chances of successfully removing a broken screw.

Method 1: Using a Screw Extractor Kit

Screw extractor kits are specifically designed to remove broken screws. Here’s how to use one effectively:

1. **Prepare the Screw:** Use a center punch and hammer to create a small indentation in the center of the broken screw. This will help guide the drill bit.
2. **Drill a Pilot Hole:** Select a drill bit that is slightly smaller than the screw extractor. Drill a pilot hole into the center of the broken screw, following the instructions provided with the extractor kit. Be careful not to drill too deep.
3. **Insert the Screw Extractor:** Insert the appropriate size screw extractor into the pilot hole. Gently tap it with a hammer to ensure it is securely seated.
4. **Turn the Extractor:** Using a wrench or tap handle, slowly turn the screw extractor counter-clockwise. Apply steady pressure and avoid forcing it. The extractor should grip the screw and begin to turn it out.
5. **Remove the Screw:** Continue turning the extractor until the broken screw is completely removed.

**Important Considerations:**

* Always use the correct size extractor for the screw.
* Apply steady, even pressure to avoid breaking the extractor.
* If the extractor slips, try using a slightly larger size or roughening the surface of the screw with a file.
* Using penetrating oil before attempting removal can ease the process.

Method 2: The Left-Handed Drill Bit Technique

Left-handed drill bits can sometimes remove a broken screw without the need for an extractor. Here’s how:

1. **Center Punch:** As with the screw extractor method, start by creating a center point on the broken screw with a center punch and hammer.
2. **Select the Right Drill Bit:** Choose a left-handed drill bit that is slightly smaller than the diameter of the screw.
3. **Drill Slowly:** Apply gentle pressure and drill into the screw at a slow, steady speed. The counter-clockwise rotation of the bit may catch the screw and begin to unscrew it.
4. **Monitor Progress:** Watch carefully as you drill. If the screw begins to turn, stop drilling and continue turning it out with the drill bit.
5. **Remove the Screw:** Once the screw is completely removed, clean the threads in the hole.

**Advantages of this method:**

* Simpler than using a screw extractor.
* Less likely to damage the surrounding material.

**Disadvantages:**

* May not work on tightly seized screws.
* Requires left-handed drill bits, which may not be readily available.

Method 3: Creating a Slot for a Flathead Screwdriver

If a portion of the screw is still protruding, you can try creating a slot in the top of the screw for a flathead screwdriver. Here’s how:

1. **Use a Dremel Tool:** Equip a Dremel tool with a cutting wheel attachment.
2. **Create a Slot:** Carefully cut a slot across the top of the broken screw, ensuring it is wide and deep enough to accommodate a flathead screwdriver.
3. **Insert Screwdriver:** Insert a flathead screwdriver into the slot.
4. **Turn the Screw:** Apply steady pressure and turn the screwdriver counter-clockwise to remove the screw.

**Tips for this Method:**

* Wear safety glasses to protect your eyes from flying debris.
* Use a slow speed on the Dremel tool to avoid overheating the screw.
* If the slot is too shallow, deepen it gradually until you can get a good grip with the screwdriver.

Method 4: Using Pliers or Locking Pliers

If enough of the screw is exposed, you might be able to grab it with pliers and twist it out.

1. **Grip the Screw:** Use needle-nose pliers or locking pliers (vise-grips) to firmly grip the exposed portion of the broken screw.
2. **Turn Counter-Clockwise:** Slowly and steadily turn the pliers counter-clockwise. Apply even pressure, and try not to let the pliers slip.
3. **Penetrating Oil:** If the screw is stuck, apply penetrating oil and let it sit for a few minutes before trying again.
4. **Remove Debris:** As you turn the screw, remove any debris or rust that accumulates around the threads.

Method 5: Heat Application

Applying heat can help loosen screws that are stuck due to corrosion or threadlocker. Here’s how to use heat safely and effectively:

1. **Apply Heat:** Use a heat gun or soldering iron to heat the area around the broken screw. Be careful not to overheat the surrounding material.
2. **Allow to Cool Slightly:** Let the area cool slightly before attempting to remove the screw. This will help prevent the screw from snapping due to thermal shock.
3. **Apply Penetrating Oil:** Apply penetrating oil to the threads of the screw.
4. **Use a Screw Extractor or Pliers:** Use a screw extractor or pliers to remove the screw, as described in the previous methods.

**Safety Precautions:**

* Work in a well-ventilated area.
* Wear heat-resistant gloves to protect your hands.
* Be careful not to overheat the surrounding material, as this could cause damage.
* Keep a fire extinguisher nearby in case of emergency.

Method 6: Welding a Nut to the Broken Screw

This method is more advanced and requires welding equipment. However, it can be very effective for removing stubborn broken screws.

1. **Clean the Area:** Clean the area around the broken screw with a wire brush.
2. **Position a Nut:** Place a nut over the broken screw, aligning the hole in the nut with the center of the screw.
3. **Weld the Nut:** Use a welder to weld the nut to the broken screw. Ensure a strong weld.
4. **Turn the Nut:** Once the weld has cooled, use a wrench to turn the nut counter-clockwise. The screw should turn out with the nut.

**Important Considerations:**

* This method requires welding skills and equipment.
* Be careful not to damage the surrounding material during welding.
* Ensure a strong weld to prevent the nut from breaking off.

Preventing Future Screw Breakages

Prevention is always better than cure. Here are some tips to help you prevent future screw breakages:

* **Use the Right Screw:** Select the correct type and size of screw for the application. Consider the material you are screwing into and the load the screw will bear.
* **Avoid Over-Tightening:** Use a torque wrench to tighten screws to the manufacturer’s recommended torque specifications. If you don’t have a torque wrench, tighten screws snugly but avoid excessive force.
* **Lubricate Screws:** Apply a lubricant, such as grease or anti-seize compound, to the threads of screws before installing them. This will help prevent corrosion and make them easier to remove in the future.
* **Use Quality Screws:** Invest in high-quality screws made from durable materials. Avoid cheap, low-quality screws, as they are more prone to breaking.
* **Drill Pilot Holes:** When screwing into hard materials, drill pilot holes to prevent the screw from binding and breaking.
* **Clean Threads:** Clean the threads of both the screw and the hole before installing the screw. This will help ensure a smooth, even fit.
* **Avoid Cross-Threading:** Be careful not to cross-thread screws during installation. Cross-threading can damage the threads and weaken the screw.
* **Regular Inspection:** Regularly inspect screws for signs of corrosion or damage. Replace any screws that are showing signs of wear.

Choosing the Right Screw Extractor: A Detailed Guide

Selecting the appropriate screw extractor is critical for successfully removing broken screws. Screw extractors come in various sizes and designs, each suited for specific screw types and sizes. Here’s a detailed guide to help you choose the right one:

1. **Determine the Screw Size:** Accurately measure the diameter of the broken screw. This will help you select an extractor that is appropriately sized.
2. **Consider the Screw Type:** Different types of screws require different types of extractors. For example, tapered extractors are best for screws with a conical shape, while straight extractors are better for screws with a cylindrical shape.
3. **Choose the Right Material:** Screw extractors are typically made from high-carbon steel or hardened alloy steel. Choose an extractor made from a durable material that can withstand the torque required to remove the broken screw.
4. **Look for Quality Construction:** Inspect the extractor for signs of quality construction. The threads should be sharp and well-defined, and the extractor should be free from defects.
5. **Read Reviews:** Read online reviews to get an idea of the performance and durability of different screw extractors.

**Types of Screw Extractors:**

* **Spiral Flute Extractors:** These extractors have a spiral flute design that provides a strong grip on the broken screw. They are best for removing screws that are tightly seized or corroded.
* **Straight Flute Extractors:** These extractors have a straight flute design that is less aggressive than spiral flute extractors. They are best for removing screws that are not tightly seized.
* **Easy Out Extractors:** These extractors have a tapered design that allows them to be easily inserted into the pilot hole. They are best for removing small screws.
* **Square Extractors:** These extractors have a square design that provides a strong grip on the broken screw. They are best for removing large screws.

By following these guidelines, you can choose the right screw extractor for your needs and increase your chances of successfully removing the broken screw.

Expert Advice on Stubborn Screws

Sometimes, despite your best efforts, a screw simply refuses to budge. Here’s some expert advice to tackle those particularly stubborn situations:

* **Patience is Key:** Don’t rush the process. Applying too much force can break the extractor or damage the surrounding material.
* **Alternate Methods:** If one method doesn’t work, try another. Experiment with different techniques until you find one that is effective.
* **Seek Professional Help:** If you are unable to remove the broken screw yourself, consider seeking professional help from a mechanic, carpenter, or other skilled tradesperson.
* **Use Impact Drivers:** An impact driver can deliver short bursts of high torque, which can help loosen stubborn screws. Use caution, as impact drivers can also break screws if used improperly.
* **Apply Vibration:** Tapping the area around the screw with a hammer can help loosen it. Use gentle taps to avoid damaging the surrounding material.

Q&A: Common Questions About Removing Broken Screws

Here are some frequently asked questions about removing broken screws:

1. **Q: What is the best penetrating oil to use for removing a broken screw?**
* **A:** Popular choices include WD-40, Liquid Wrench, and PB B’laster. PB B’laster is often considered one of the most effective for heavily corroded screws.
2. **Q: Can I use a regular drill bit instead of a left-handed drill bit?**
* **A:** Yes, but a left-handed drill bit is more likely to catch the screw and unscrew it. A regular drill bit may simply drill a hole through the screw.
3. **Q: How do I prevent the screw extractor from breaking?**
* **A:** Use the correct size extractor, apply steady pressure, and avoid forcing it. Ensure the pilot hole is properly centered and not too deep.
4. **Q: What should I do if the screw extractor breaks inside the screw?**
* **A:** This is a tricky situation. You may need to use a smaller extractor to remove the broken extractor, or you may need to drill out the entire screw and extractor. This often requires professional help.
5. **Q: How do I remove a broken screw from plastic?**
* **A:** Be extra careful when working with plastic, as it is easily damaged. Use gentle heat and avoid excessive force. A screw extractor or pliers may be effective.
6. **Q: Is it possible to remove a broken screw without any special tools?**
* **A:** Yes, if enough of the screw is exposed, you may be able to grip it with pliers and twist it out. Creating a slot for a flathead screwdriver is another option.
7. **Q: What is the best way to clean the threads after removing a broken screw?**
* **A:** Use a thread chaser or tap to clean the threads. You can also use a wire brush or compressed air.
8. **Q: Can I use super glue to attach something to the broken screw and twist it out?**
* **A:** While tempting, this is generally not recommended. Super glue is often not strong enough to withstand the torque required to remove a stuck screw and can make future removal attempts more difficult.
9. **Q: What if the screw is recessed and I can’t get pliers or a Dremel to it?**
* **A:** In this case, a screw extractor is often the best option. Make sure you can still create a pilot hole. Alternatively, you might need to carefully drill away some of the surrounding material to expose more of the screw.
10. **Q: How do I deal with a screw that’s both broken and rusted solid?**
* **A:** This is one of the toughest scenarios. Multiple applications of penetrating oil, combined with heat, are usually required. Patience is key. Welding a nut might also be a good option if feasible.

Conclusion: Mastering the Art of Broken Screw Removal

Removing a broken screw can be a frustrating experience, but with the right knowledge, tools, and techniques, it’s a problem that can be overcome. This guide has provided you with a comprehensive overview of the most effective methods, from using screw extractors and left-handed drill bits to applying heat and creating slots for screwdrivers. Remember to always prioritize safety, use the correct tools, and be patient. By following these guidelines, you’ll be well-equipped to tackle any broken screw situation that comes your way. Now that you’re armed with this knowledge, share your own experiences or any additional tips you have in the comments below. Have you tried any of these methods? What worked best for you? Let’s learn from each other and conquer those broken screws together!